Assembly

Transmission









Transmission Assembly - Housings













Transmission Assembly - Internal Components

















NOTE: Apply threadlock to all bolt threads during assembly.

1. NOTICE: Do not reassemble the transmission dry. Apply lubricant throughout the assembly procedure or damage to the transmission can occur on start-up.

Lubricate all bearings, gears and synchronizers with the recommended transmission lubricant.

2. Install the countershaft assembly in the transmission case.

3. Install the 2 reverse idler bearings and spacer into the reverse idler gear.





4. Install the reverse idler gear.





5. Install the reverse idler shaft.





6. NOTE: Install bearings and cups in matched sets only.

Install the new countershaft rear bearing and cup.





7. Install the rear bearing retainer and the 4 bolts.
- Tighten to 37 Nm (27 lb-ft).





8. Using the Dial Indicator Gauge with Holding Fixture, measure the countershaft end play.

1. Place the transmission in a vertical position and install the Dial Indicator Gauge with Holding Fixture.

2. Push upward on the countershaft.

3. Record the Dial Indicator Gauge reading.





NOTICE: Although zero end play is the ideal, end play up to 0.12 mm (0.004 in) is an acceptable tolerance. Do not overload the bearings with a shim that is too thick as damage may occur.

9. If necessary, add a shim(s) behind the rear bearing retainer to adjust end play.

10. NOTE: This step is necessary to gain clearance when installing the mainshaft.

Remove the 4 rear bearing retainer bolts, retainer and cup.





11. Using a rope wrapped around the front of the mainshaft, position the rear of the mainshaft though the transmission case and lower the front of the mainshaft down into the transmission main case.

12. Using a suitable tool and press, install the input shaft bearing.





13. Install the input shaft.





14. Install the bearing cup and shim(s) onto the input shaft.





15. Apply a 3.2 mm (1/8 in) bead of sealant to the sealing surface of the front bearing retainer. Install the front bearing retainer and the 4 bolts.
- Tighten to 19 Nm (168 lb-in).





16. Install the cup, rear bearing retainer and the 4 rear bearing retainer bolts.
- Tighten to 37 Nm (27 lb-ft).





17. Install the ball bearing and the 2 roller bearings with the spacer between the bearings.





18. Install the 5th gear synchronizer assembly.





19. Install the new snap ring on the 5th gear clutch cone.





20. Install the front and rear yoke spacers with the ball bearing between the spacers.





21. Apply a 3.2 mm (1/8 in) bead of sealant to the sealing surface on the rear of the transmission main case and install the extension housing.

22. Install the 9 extension housing-to-transmission main case bolts and stud.
- Tighten to 62 Nm (46 lb-ft).





23. Install the transmission mount and 2 new bolts.
- Tighten to 62 Nm (46 lb-ft).





24. Install the fuel tube support bracket and the bracket nut.
- Tighten to 62 Nm (46 lb-ft).





25. Using the Drive Pinion Flange Holding Fixture, install the transmission flange washer and retainer nut.
- Tighten to 160 Nm (118 lb-ft).





26. Using the Dial Indicator Gauge with Holding Fixture, measure the mainshaft end play.

1. Place the transmission in a vertical position and install the Dial Indicator Gauge with Holding Fixture.

2. Push upward on the mainshaft.

3. Record the Dial Indicator Gauge reading.





NOTICE: Although zero end play is the ideal, end play up to 0.12 mm (0.004 in) is an acceptable tolerance. Do not overload the bearings with a shim that is too thick as damage may occur.

27. If necessary, add a shim(s) behind the front bearing retainer to adjust end play.

28. Apply a 3.2 mm (1/8 in) bead of sealant to the sealing surface of the shift control housing. Install the shift control housing and the 10 bolts.
- Tighten to 27 Nm (20 lb-ft).





29. Install the vent hose support bracket bolt.
- Tighten to 16 Nm (142 lb-in).





30. Remove the transmission from the Transmission Holding Fixture and place on the bench.





31. Install the clutch housing and the 2 clutch housing-to-transmission case nuts.
- Tighten to 62 Nm (46 lb-ft).





32. Install the 4 clutch housing-to-transmission case rear bolts.
- Tighten to 62 Nm (46 lb-ft).